Expandable easy opening dough package

ABSTRACT

An easy opening flexible package is provided. The package is suitable for containing raw dough and other products, especially products that create pressure within the package by expansion or by giving off gas such as carbon dioxide.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention patent relates to an expandable easy opening package.More particularly, this invention relates to a flexible package havingan easy opening feature especially suitable for holding raw dough underpressure.

Description of the Related Art

Dough for cookies and biscuits and the like is purchased predominatelyin composite cans having metal ends. The cylindrical can is rigid andstrong enough to hold the internal pressures as the newly made doughexpands to fill the internal space. When the can label is removed, thecan body bursts open along a spiral seam to release the internalpressure, allowing access to the dough.

Dough cans must be engineered to accommodate certain natural phenomenacaused by the packaged dough. For example, the gas which occupies theempty headspace in the dough can after it is immediately filled needs tobe vented as the expanding dough takes up the empty space in the can anddisplaces this gas. Also, carbon dioxide (CO₂) given off by the doughduring its shelf life needs to be vented to prevent unwanted (premature)bursting. The headspace gas and CO₂ venting typically is accomplishedthrough a small opening in the seam between the metal ends and thecomposite can body.

The present invention provides an alternative to conventional compositedough cans.

BRIEF SUMMARY OF THE INVENTION

The present invention is an easy opening flexible package, suitable forholding raw dough and other products, especially products that createpressure by expanding within the package.

The flexible package may be made of a laminate film comprising aflexible scored inner layer and a flexible scored outer layersubstantially coextensive with and laminated to the inner layer by apressures sensitive adhesive and a permanent adhesive. The inner layermay comprise a barrier layer. The outer layer may be transparent and maybear reverse printing on an inner facing surface. A metal foil layer maybe interposed between the inner layer and the outer layer. The laminatefilm can now be rolled up to form a cylindrical package having a pulltab for opening.

The pressure sensitive adhesive is pattern applied or otherwise locatedin a first predetermined pattern on the outer facing surface of theinner layer. The first predetermined pattern may be U-shaped andcomprise two elongated sides and a bottom connecting the sides of the“U”.

The permanent adhesive may be pattern applied or otherwise located in asecond predetermined pattern on the outer facing surface of the innerlayer outside of the first predetermined pattern, i.e., i.e., outsidethe U-shaped region of the pressure sensitive adhesive.

A heat seal is disposed between the inner layer and the outer layeralong an area of the inner layer that will be scored to create andundercut. The heat seal is designed to hold the undercut closed until apredetermined length of a pull tab is lifted from the package.

The undercut is formed by laser scoring or other suitable means in theinner layer within an area underlying the heat seal. The undercut has astarter end near a gripping end of the pull tab. The undercut may belinear and may extend spirally around part of the cylindrical package.

The overcut is formed by laser scoring or other suitable means in theouter layer in substantial registration with the pressure sensitiveadhesive and substantially surrounds the undercut. The overcut may beU-shaped and defines the perimeter of the pull tab.

The flexible package may be cylindrical shaped and have a volume andopposing ends. One or more frangible seams may be formed in the packagethat fracture in response to internal pressure, expanding the packagevolume and relieving any internal pressure caused by, for example, doughexpansion.

One or more tortuous paths (vents) may be formed in one or both ends ofthe package to release gas during the shelf life of the packagecontents.

Preferably the permanent adhesive does not cover a non-adhesive area onthe outer surface of the inner layer located under a gripping end of thepull tab so that the gripping end is free and can be easily lifted by auser.

To use the package, the use pulls on the pull tab. When a sufficientlength of the undercut is exposed the heat seal fails and the undercutbursts open under pressure, exposing the contents of the package.

Micro-perforations may be formed in the inner layer, under the pull tab,between the undercut and the non-adhesive area, to release a smallamount of pressure to lessen the bursting effect when the package isopened.

In another aspect of disclosure a method of making a flexible easyopening package is provided, comprising the steps of:

providing an inner layer of flexible material and an outer layer offlexible material in sheet form;

pattern applying a pressure sensitive adhesive to an outer facingsurface of the inner layer in a first predetermined area of the innerlayer;

drying the pressure sensitive adhesive on the inner layer;

applying a permanent adhesive onto the outer facing surface of the innerlayer in a second predetermined area such that the permanent adhesivedoes not cover the pressure sensitive adhesive;

applying a heat seal to the outer facing surface of the inner layer;

adhesively joining the inner layer and the outer layer via the pressuresensitive adhesive and the permanent adhesive to form a laminate film;

forming an undercut in the inner layer which is in substantialregistration with the heat seal; and

forming an overcut in the outer layer 16 substantially in registrationwith the pressure sensitive adhesive, the overcut defining an elongatedpull tab.

The method may include the additional step of forming micro-perforationsin the inner layer in an area of the inner layer that, upon lifting thepull tab, is exposed before the undercut.

The heat seal may be formed according the following steps:

applying a sealant to an outer facing surface of the inner layer;

applying a sealant coating on top of the sealant; and

heating the sealant coating and the sealant to form the heat seal.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a dough package according to thedisclosure after being initially filled with dough.

FIG. 2 is a perspective view of the dough package of FIG. 1 after thedough has expanded.

FIG. 3 is a perspective view of the dough package of FIG. 2 after thepull tab has been lifted but before the package bursts.

FIG. 4 is a close up cross-sectional view of a laminate used to make thedough package of FIG. 2 before heat is applied to the sealant andsealant coating covering the undercut.

FIG. 5 is a close up cross-sectional view of the laminate of FIG. 3after heat has been applied to the sealant and heat seal coating to forma heat seal.

DETAILED DESCRIPTION OF THE INVENTION

While this invention may be embodied in many forms, there is shown inthe drawings and will herein be described in detail one or moreembodiments with the understanding that this disclosure is to beconsidered an exemplification of the principles of the invention and isnot intended to limit the invention to the illustrated embodiments.

Turning to the drawings, there is shown in the figures one embodiment ofthe present invention, a flexible dough package 10 having a packageexpansion feature, a vent feature and an easy opening feature. At itsmost general, the package 10 is made from a laminate film 12 such asthat shown in FIG. 5 and comprises a scored inner layer 14 and a scoredouter layer 16 laminated together with both permanent adhesive 18 andpressure sensitive adhesive 20.

The inner layer 14 may be made of polyolefin film or any suitablematerial and typically is about 30 to 70 microns thick. The inner layer14 may also comprise multiple layers of various materials, including forexample, a barrier layer providing a barrier against the passage ofoxygen and/or moisture, and a sealant layer. The inner layer 14 has aninner facing (product facing) surface 22 and an outer facing surface 24.

The outer layer 16 may be made of polyester film or any suitablematerial and typically is about 30 microns thick. The outer layer 16 hasan inner facing surface 26 and an outer facing surface 28. The outerlayer 16 may be transparent and may bear reverse printing on its innerfacing surface 26. Prior to being joined to the inner layer 14, theinner facing surface 26 of the outer layer 16 can be treated by a coronadischarge or similar apparatus to render the inner facing surface 26more receptive to ink and/or more readily bondable to thepressure-sensitive adhesive 20.

An optional metallization layer or foil layer (not shown in the figures)may be interposed between the inner layer 14 and the outer layer 16. Themetallization layer or foil layer can be helpful in preventing a laserfrom penetrating through the entire thickness of the laminate film 10 asdescribed more fully below.

The package 10 may be filled with raw dough or other suitable content 30and then closed at one or both ends 32, preferably by heat sealing theends 32. The package 10 may be generally cylindrically shaped as shownin FIGS. 1 to 3 or have any other suitable shape.

The package 10 may have one or more of the following features:

Package Expansion Feature (Frangible Seam)

When raw dough 30 is initially placed into the package 10 the dough 30can expand. Providing an expandable package 10 to let the dough 30expand eliminates or minimizes the need to include headspace in thepackage 10 as it is initially filled. To accomplish this, the package 10may have one or more built-in frangible seams 34 that can fracture(break) at the interface of the frangible seam bond, expanding thepackage volume and relieving any internal pressure caused by the doughexpansion.

Each frangible seam 34 can be formed by folding the laminate film 12 tocreate a seam or folded area, and then securing the seam or folded areain place using a heat activated seal coating, heat seal web or othersuitable means. If a heat activated seal coating is used, the coatingmay be pattern applied over the seam 34. Alternatively, a heat seal webmay be coextruded with the package film under low temperature. The outerfacing surface of the heat activated seal coating or the heat seal webmay be corona treated to provide a print receptive surface.

The pattern of each frangible seam 34 can be varied based on the shapeof the initial filled package 10 and the final desired shape of theexpanded package 10. For example, the frangible seams 34 may take theshape of fins on a package that will morph into a larger diameter afterexpanding. Different dough formulas may require different expansion seamconfigurations. Multiple frangible seams can be added to the package 10even if some never deploy during expansion of the package 10.

FIG. 1 is a perspective view of a flexible dough package 10 according tothe disclosure after being initially filled with dough 30. The dough 30occupies most or all of the interior space of the package 10 and thefrangible seams 34 are intact (unbroken). However, as the dough 30expands, the frangible seams 34 are broken which allows the package 10to expand until it occupies the larger volume indicated by the brokenlines 36.

FIG. 2 is a perspective view of the dough package 10 of FIG. 1 after theexpanding dough 30 has caused the package 10 to expand. The frangibleseams 34 are shown in their broken state, and the package 10 nowoccupies the volume indicated by the broken lines 36 in FIG. 1.

Venting Feature

Even after the dough 30 expands, the dough 30 can give off carbondioxide (CO₂) during the shelf life of the dough. The CO₂ needs to bevented outside the package 10 to prevent unwanted (premature) burstingof the package 10. To achieve this, one or more vents 38 can be formedin one or both ends 32 of the package 10 by micro-perforating one orboth ends 32 with a laser, or by leaving a tortuous path 38 in the heatsealed end 32 to allow gas such as CO₂ to escape. This venting featuretakes the place of the seam vent(s) found in conventional dough cansbetween the metal ends and the composite can body.

The length of the tortuous path 38 typically is about 1500 times thediameter to be effective. The tortuous path 38 remains closed and theinterior of the package 10 isolated from the surroundings until theinterior and the tortuous path 38 are subjected to sufficient pressure.When sufficient pressure is built up from, say, CO₂, the gas can exitthe package 10 through the tortuous path in a process referred to asdiffusion. The dough 30 may caulk (seal) the vent 38 after the gas hasbeen vented, or the vent 38 may automatically seal itself when thetortuous path pressure is reduced.

Alternatively, the package 10 may be made using suitable films that areCO₂ gas permeable and selected to allow gas transmission through thelaminate film 12 during the lifetime of the package contents 30.

Easy Opening Feature

The dough package 10 may include an easy opening feature which allowsthe package 10 to burst open only after the user pulls sufficiently on apull tab 42.

The easy opening feature requires the double layer laminated film 12described above. Permanent and pressure sensitive adhesives are appliedbetween the inner and outer layers in predetermined patterns. Once thelaminate film 12 is formed, precise scoring operations are performed oneither side of the laminate film 12 in registration with the adhesivepatterns or in registration with a heat seal 60, with each scoringoperation only penetrating through one layer of the laminate film 12.For example, a substantially linear undercut 44 is formed in the innerlayer 14 in registration with a heat seal 60 without cutting or scoringthe outer layer 16. Likewise, a generally U-shaped overcut 46 is formedin the outer layer 16 in registration with the pressure sensitiveadhesive pattern 20 without cutting or scoring the inner layer 14. Thescoring operations result in a package 10 having a pull tab 42 that,when lifted a sufficient amount, exposes the heat sealed undercut 44,causing the package 10 to burst along the undercut 44 and exposing thecontents 30.

FIG. 3 is a perspective view of a dough package 10 after the pull tab 42has been partially lifted but before the package 10 has burst. Theundercut 44 is exposed but remains intact due to the heat seal 60.

Preferably the undercut 44 extends spirally around part of thesubstantially cylindrical package 10, and may extend from near one end32 of the package 10 to near an opposite end 32. The undercut 44 may beformed with a laser, with a die cutting machine or by any suitable meansand extends through the entire thickness or almost the entire thicknessof the inner layer 14 but not the outer layer 16. If the dough package10 has a metallized layer or foil layer, then the metallized layer orfoil layer can serve as a natural stop for the laser. Because of theundercut 44, the inner layer 14 will be weak enough to burst open alongthe exposed undercut 44 when a predetermined length of the pull tab 42is pulled away from the inner layer 14.

The pressure sensitive adhesive (PSA) 20 is pattern applied to the outerfacing surface 24 of the inner layer 14 on either side of the area thatwill become the undercut 44. The PSA 20 may be applied in substantiallya U-shape, with the sides 48 of the “U” being substantially coextensivewith the undercut 44 and the bottom 50 of the “U” connecting the sides48 along an area beyond the starter end 45 of the undercut 44, i.e., theend 45 of the undercut 44 that is first exposed when the pull tab 42 ispulled.

The overcut 46 may form a U-shaped pattern with side cuts 52 connectedby an end cut 54 to define the elongated pull tab 42. The side cuts 52may be located on either side of the undercut 44 and preferably aresubstantially co-extensive with the undercut 44. The overcut 46preferably is formed in registration with the PSA 20. That is, theovercut 46 should substantially overlap the PSA 20 so that the pull tab42 is releasable from the inner layer 14. The overcut 46 may be formedwith a laser, with a die cutting machine or by any suitable means andmay extend through the entire thickness or almost the entire thicknessof the outer layer 16. Preferably the overcut 46 substantially surroundsthe undercut 44.

The permanent adhesive 18 may be applied to the outer facing surface 24of the inner layer 14 so that the permanent adhesive 18 does not coverthe PSA 20. Preferably the permanent adhesive 18 does not cover the(non-adhesive) area 55 of the inner layer 14 located under the freegripping end 56 of the pull tab 42 so that the gripping end 56 is notadhered to the inner layer 14. More specifically, the permanent adhesive18 is located in an area outside the region defined by the pressuresensitive adhesive 20.

A heat seal 60 is disposed between the inner layer 14 and the outerlayer 16 overlaying the undercut 44 to hold the undercut closed until asufficient length of the pull tab 42 is lifted from the package 10. Theheat seal 60 may be made by heating a sealant 62 and a sealant coating64 as will now be explained. The heat seal 60 should hold the undercut44 closed but not permanently adhere to the outer layer 16.

To make the heat seal 60, a sealant 62 may be applied to the outerfacing surface 24 of the inner layer 14 so that it covers the undercut44, and a sealant coating 64 may be applied on top of the sealant 62 asshown in FIG. 4. When the sealant 62 and sealant coating 64 are heated,they form the heat seal 60 shown in FIG. 5. As already noted, the heatseal 60 can withstand the internal pressure forces of the dough package10 until the pull tab 42 is sufficiently pulled away from the innerlayer 14.

Optional micro-perforations 66 may be formed in the inner layer 14 whereit underlies the top portion of the pull tab 42 to relieve pressure andmitigate the bursting effect caused when the pull tab 42 is pulled. Themicro-perforations 66 should be located in an area of the inner layer 14that, upon lifting the pull tab 42, is exposed just before the undercut44 is exposed. For example, the micro-perforations 66 may be located ina linear array of three within the elongated rectangular area defined bythe PSA 20, under the pull tab 42, and between the undercut 44 and theadhesive-free area 55 as shown in FIG. 3.

Referring to FIG. 5, the preferred structure of the package 10 is, frominside out, a scored barrier layer 14 of polyethylene terephthalate(PET), a middle adhesive layer comprising PSA 20 plus heat seal 60 pluspermanent adhesive 18, and a scored outer layer 16 of PET. The innerfacing surface 26 of the outer layer 16 may bear ink printing such as aproduct label.

Method of Making a Dough Package with Easy Opening Feature

An easy opening dough package 10 may be made in the following manner:

Providing an inner layer 14 of flexible material and an outer layer 16of flexible material in sheet form.

Pattern applying a PSA 20 to an outer facing surface 24 of the innerlayer 14 in a predetermined area of the inner layer 14. The pattern maybe any suitable pattern but preferably is in a U-shape pattern havingtwo substantially linear sides 48 connected at a bottom 50.

Drying the PSA 20 on the inner layer 14 at a drying station, such as anoven or the like.

Applying a permanent adhesive 18 onto the outer facing surface 24 of theinner layer 14 such that the permanent adhesive 18 does not cover thePSA 20. Preferably the permanent adhesive 18 also does not cover an area55 of the inner layer 14 located under the gripping end 56 of the pulltab 42 so that the gripping end 56 is not adhered to the inner layer 14.However, the permanent adhesive 18 should cover a substantial portion ofthe inner layer 14 to permit it to be laminated to the outer layer 16.

Applying a sealant 62 to the outer facing surface 24 of the inner layer14 which will be substantially coextensive with an undercut 44 to beformed in a subsequent step.

Applying a sealant coating 64 on top of the sealant 62.

Adhesively joining the inner layer 14 and the outer layer 16 via the PSA20 and the permanent laminating adhesive 18 to form a laminate film 12.This may be accomplished using a laminating machine comprising tworollers forming a nip therebetween as known in the art. The inner layer14 and the outer layer 16 should be substantially coextensive with eachother during the laminating process. For example, if the layers arerectangular, the width and length of the inner layer 14 should match thewidth and length of the outer layer 16. The laminate 12 film may berectangular or any shape suitable for forming a dough package 10, andpreferably a cylindrical dough package 10.

Feeding a roll of the laminate film 12 to first scoring station, andscoring an undercut 44 in the inner layer 14. The undercut 44 may belinear or any suitable shape and may extend spirally around the finishedpackage 10. The undercut 44 may be formed with a laser, with a diecutting machine or by any suitable means and may extend through theentire thickness or almost the entire thickness of the inner layer 14.The undercut 44 should be in registration with the sealant 62 and sealcoating 64. That is, the undercut 44 should be made within the elongatedrectangular-shaped area defined by the sealant 62 and seal coating 64(which, as noted below, will be bonded under heat to form a heat seal60).

Forming micro-perforations 38 in the inner layer 14 in an area of theinner layer 14 that, upon lifting the pull tab 42, is exposed before theundercut 44.

Forming an overcut 46 in an outer facing surface 28 of the outer layer16. The overcut 46 preferably is formed substantially in registrationwith the PSA 20. That is, the overcut 46 should substantially overlapthe PSA 20. In the illustrated example, the overcut 46 forms a U-shapedpattern with sides 52 connected by a curved bottom 54 to define anelongated pull tab 42. The sides 52 are located on either side of theundercut 44 and preferably are substantially co-extensive with theundercut 44. Preferably the curved bottom 54 extends outside theelongated rectangular area of the PSA 20 (and outside the area coveredin permanent adhesive 18) to form the gripping end 56 that is notadhered to the inner layer 14. The overcut 46 may be formed with alaser, with a die cutting machine or by any suitable means and mayextend through the entire thickness or almost the entire thickness ofthe outer layer 16.

Heating the laminate film 12 so that the sealant 62 and sealant coating64 form a heat seal 60. In the finished package 10 the heat seal 60 willkeep the undercut 44 closed until the pull tab 42 is sufficiently liftedaway from the package body. The heating may be achieved with a heatroller or other suitable means. FIG. 5 is a close up cross-sectionalview of the laminate film 12 after heat has been applied to form theheat seal 60.

The laminate film 12, shown in FIG. 5, can now be rolled up for use inpackaging products. For example and without limitation, the laminatefilm 12 can be used to wrap raw dough 30 at a dough making facility.After the dough 30 is wrapped, the ends 32 may be sealed to create thefilled dough package 10 shown in FIG. 1. The heat sealing may beaccomplished by crimping, folding or otherwise closing off the ends 32and then exposing the ends 32 to a temperature sufficient to at leastpartially melt the film so that it fuses or welds together to form aheat seal.

Preferably, the manufacturing process includes steps for makingfrangible seams 34 for package expansion and vents 38 for CO₂ gasrelease according to the following optional steps:

Forming one or more frangible seams 34 in the laminate film 12.

Forming a tortuous path 38 in one or both sealed ends 32.

Opening the Dough Package

The flexible dough package 10 can be opened by pulling the gripping end56 formed in the outer layer 16 but not adhered to the inner layer 14.Once the gripping end 56 is pulled, the optional micro-perforations 66are exposed, which gently releases some of the pressure within thepackage 10. Continued pulling on the gripping end 56 exposes more andmore of the undercut 44. The heat seal 60 disposed over the undercut 44may initially withstand the internal pressure forces of the doughpackage 10 until a sufficient length of the pull tab 42 is pulled awayfrom the inner layer 14. Since the heat seal 60 ultimately cannotwithstand the internal pressure, the package 10 essentially bursts openalong the undercut 44 to expose the dough 30 for dispensing.

* * *

It is understood that the embodiments of the invention described aboveare only particular examples which serve to illustrate the principles ofthe invention. Modifications and alternative embodiments of theinvention are contemplated which do not depart from the scope of theinvention as defined by the foregoing teachings and appended claims. Itis intended that the claims cover all such modifications and alternativeembodiments that fall within their scope.

The invention claimed is:
 1. A pressurized flexible package for holdingcontents under pressure, the package comprising: a flexible laminatefilm comprising a flexible inner layer and an outer layer coextensivewith and laminated to the inner layer; an undercut formed only in theinner layer and having a starter end; an overcut formed only in theouter layer and surrounding the undercut, the overcut defining a pulltab region; a pressure sensitive adhesive located in a firstpredetermined pattern on the outer facing surface of the inner layer andin substantial registration with the overcut, the first predeterminedpattern located within the pull tab region and comprising two elongatedsides located on either side of the undercut and a bottom connecting thesides; a permanent adhesive located in a second predetermined patternbetween the inner layer and the outer layer outside the pull tab region;and an easy opening feature formed in the package, the easy openingfeature comprising: a pull tab formed in the outer layer and having alength and a perimeter defined by the overcut; and a heat seal disposedbetween the inner layer and the outer layer and in substantialregistration with the undercut but not the overcut, the heat seallocated within an area defined on three sides by the predeterminedpattern of the pressure sensitive adhesive and on a fourth side by thesecond predetermined pattern; wherein the heat seal withstands internalpressure forces of the contents and remains intact until a predeterminedlength of the pull tab is pulled away from the inner layer, whereuponthe heat seal is broken and the package bursts open along the undercutto expose the contents.
 2. The flexible package of claim 1 wherein: theinner layer comprises a barrier layer.
 3. The flexible package of claim1 wherein the heat seal comprises: a sealant on top of the outer facingsurface of the inner layer and covering the undercut, and a sealantcoating on top of the sealant.
 4. The flexible package of claim 1further comprising: a metal foil layer interposed between the innerlayer and the outer layer.
 5. The flexible package of claim 1 wherein:the flexible package is generally cylindrically shaped, has a volume andopposing ends, and is filled with raw dough.
 6. The flexible package ofclaim 5 further comprising: one or more frangible seams that fracture inresponse to internal pressure, expanding the package volume andrelieving any internal pressure caused by dough expansion.
 7. Theflexible package of claim 5 further comprising: one or more tortuouspath vents formed in one or both ends of the package.
 8. The flexiblepackage of claim 1 wherein: the undercut consists essentially of asingle linear undercut.
 9. The flexible package of claim 5 wherein: theundercut extends spirally around part of the flexible package.
 10. Theflexible package of claim 1 wherein: the first predetermined pattern isa U-shape; the elongated sides are coextensive with the undercut; andthe bottom extends along an area beyond the starter end of the undercut.11. The flexible package of claim 1 wherein: the overcut has a U-shapedpattern comprising side cuts connected by an end cut.
 12. The flexiblepackage of claim 11 wherein: the side cuts are located on either side ofthe undercut and are co-extensive with the undercut.
 13. The flexiblepackage of claim 11 wherein: the overcut overlaps the firstpredetermined pattern so that the pull tab is releasable from the innerlayer.
 14. The flexible package of claim 1 wherein: the permanentadhesive does not cover a non-adhesive area (55) of the inner layerlocated under a gripping end (56) of the pull tab so that the grippingend is not adhered to the inner layer.
 15. The flexible package of claim1 wherein: the heat seal is adapted to withstand internal pressureforces of the flexible package until a sufficient length of the pull tabis pulled away from the inner layer.
 16. A pressurized flexible packagefor holding contents under pressure, the package comprising: a flexiblelaminate film comprising a flexible inner layer and an outer layercoextensive with and laminated to the inner layer; an undercut formedonly in the inner layer and having a starter end; an overcut formed onlyin the outer layer and surrounding the undercut, the overcut defining apull tab region; a pressure sensitive adhesive located in a firstpredetermined pattern on the outer facing surface of the inner layer andin substantial registration with the overcut, the first predeterminedpattern comprising two elongated sides located on either side of theundercut and a bottom connecting the sides; a permanent adhesive locatedin a second predetermined pattern between the inner layer and the outerlayer outside the pull tab region; and an easy opening feature formed inthe package, the easy opening feature comprising: a pull tab formed inthe outer layer and having a length and a perimeter defined by theovercut; and a heat seal disposed between the inner layer and the outerlayer and overlaying the undercut; wherein the heat seal withstandsinternal pressure forces of the contents and remains intact until apredetermined length of the pull tab is pulled away from the innerlayer, whereupon the heat seal is broken and the package bursts openalong the undercut to expose the contents; and wherein the permanentadhesive does not cover a non-adhesive area of the inner layer locatedunder a gripping end of the pull tab so that the gripping end is notadhered to the inner layer; the package further comprisingmicro-perforations formed in the inner layer between the undercut andthe non-adhesive area, the micro-perforations underlying a top portionof the pull tab and located within an area of the inner layer that iscompletely sealed from the outside by the pressure sensitive adhesiveand the heat seal, the area located between the bottom of the pressuresensitive adhesive pattern and the heat seal such that, upon lifting thepull tab, the micro-perforations are exposed before the undercut isexposed.